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Zee, my experience with Lexan is limited, but positive.
Here's the heart of it: Lexan (all polycarbonates?) are MADE to deform.
It deforms, for instance, to accept the blow of a baseball bat... or a bullet (in thicker sheets, please!).
This stuff is really quite soft, relatively speaking.
1. So it deforms. Good!
2. You can slice it and dice it with woodworking tools. Good!
3. But it scratches when you look at it hard. Not good. (Which is why I made the comment about the pricier scratch-resistant variety).
To bend beyond what comes readily: apply slow heat.
I mean, you can MELT this stuff quickly with a propane torch.
(Good for cleaning up -- smoothing -- cut edges.)
A hair dryer or equivalent works well, or a torch waved over a largish area.
Test first, right? :-)
Up here in the Land of the Ice Scraper it's the scratches that are on my mind.
--
Gregg in MN
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